Material conversion apparatus

ABSTRACT

A material conversion apparatus includes: (a) a housing, (b) a chamber for treating the material disposed within the housing, (c) an induction coil surrounding the chamber and (d) means for exhausting or evacuating the treated content of the chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a completion application of co-pending U.S. Patent Application Ser. No. 63/139,851, filed Jan. 21, 2021 for “Material Conversion Apparatus”, the disclosure of which is hereby incorporated by reference, in its entirety, including the drawing.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention pertains to material conversion apparatus. More particularly, the present invention concerns induction apparatus for the conversion of various materials. Even more particularly, the present invention concerns industrial apparatus for the conversion of various synthetic and natural materials into predominantly a gas.

2. Prior Art

As is known to those skilled in the art to which the present invention pertains, waste materials are of great environmental concern. Today most waste materials are either incinerated in giant gas or otherwise fired incinerators or in landfills. Landfills are used in today's environment as a disposal method for non-biodegradable and non-reusable or recyclable materials. Landfills and their runoffs create potential pollution problems affecting water supplies throughout the globe.

Gas fired incinerators also create problems due not only to the excessive heat which must be generated by them and their concomitant consumption of fuel(s) which, typically, are a byproduct of oil drilling or the like. Also, incinerators emit pollutants into the atmosphere and, at the same time, are incapable of reducing various materials to the point where they can easily be disposed of or otherwise converted.

Induction furnaces, on the other hand, are typically electrically operated carbon reducing footprints. They can be operated at high temperatures for reducing, vaporizing, pyrolyzing or plasticizing materials. Thus, there exists a need for new and improved electrical induction apparatus which can be used to convert waste, biowaste, and other materials with little to no pollution associated therewith.

The present invention is directed to such improvements.

SUMMARY OF THE INVENTION

In accordance with the present there is provided a material conversion apparatus or an induction furnace which, generally, comprises: (a) a housing, (b) a chamber for treating material disposed within the housing, (c) an induction coil surrounding the chamber and (d) means for exhausting or evacuating the treated or residual content or material in the chamber.

The housing can have any suitable geometric configuration, such as cylindrical, rectangular, or the like. The housing is an insulating element or member which is formed from any material capable of withstanding the elevated temperatures ordinarily associated with induction heating and which surrounds the chamber.

Suitable materials include refractory materials, ceramic fibers, and the like.

The chamber, itself, is supported within the housing by any suitable means such as bracketry, stanchions, stands or the like.

The chamber, like the housing, can take on any suitable configuration including cylindrical, rectangular or the like. The chamber is formed from suitable materials such as steel, stainless steel, iridium, molybdenum, Inconel, other alloys and the like. The criteria associated with the chamber material is that it be capable of having the energy from the coil transferred and then conducted and radiated into its interior.

The induction coil surrounds and envelops the chamber and creates sufficient heat which penetrates through the walls of the chamber to pyrolyze, incinerate or otherwise heat the waste material contained therein to the point where it is reduced to ashes, vaporized, melted if a plastic, or otherwise rendered disposable.

The induction coil is constructed of copper wire, copper tubing, copper windings, aluminum, aluminum windings, zinc, or nickel or any other type of low resistance materials. The coil may be used dry or fluid cooled during use.

Where burning for disposal is desired, the present apparatus may include means for exhausting. The means for exhausting, preferably, includes an exhaust stack or tube in fluid communication with the chamber and a blower or fan disposed upstream of the chamber and in communication with the stack. The fan creates a negative pressure to draw any solids material or vapor up through the exhaust stack.

An induction thermal oxidizer may be used after the fan for the post treatment of materials.

The means for exhausting may further include a secondary exhaust tube connected to the afterburner which opens to the atmosphere.

Recovery of the vapors is predicated on the material being processed. Thus, there can be recovery after additional treatment.

The housing may be arranged either horizontally or vertically if housing space is limited.

For a more complete understanding of the present invention reference is made to the following detailed description and accompany drawing. In the drawing, like reference characters refer to like parts throughout the several views in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cut-away view of a first embodiment hereof;

FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

FIG. 3 is a cut-away view of a second embodiment hereof;

FIG. 4 is a cut-away view of a third embodiment hereof;

FIG. 5 is a cross-sectional view taken along lines 5-5 of FIG. 4; and

FIG. 6 is a cut-away view of a third embodiment hereof.

DESCRIPTION OF THE INVENTION

Now, and in accordance with the present invention and with reference to FIGS. 1 and 2, there is provided material conversion apparatus, generally, denoted at 10. The apparatus hereof generally comprises: (a) a housing 12, (b) a chamber 14 for treatment of the material to be converted, disposed in the housing (c) an induction coil 16 which surrounds the chamber and (d) means 18 for exhausting or evacuating the past conversion content of the chamber.

With more particularity the housing 12 comprises a barrel or drum 20 which is formed from any suitable insulating-type material. It is to be understood that the geometry of the barrel is not critical hereto. Thus, it may be cylindrical, rectangular or any other geometric configuration that is suitable for the materials to be treated. Preferably, the housing is formed from a refractory material or ceramic material which can easily withstand the temperatures which are generated within the chamber 14.

As shown in the drawing, the waste material treatment chamber 14 is disposed within the housing, substantially centrally thereof.

Although not shown in the drawing the chamber is supported within the housing by any suitable means such as bracketry, posts, stanchions or the like which are formed from materials suitable for withstanding the temperatures generated within the interior of the housing. The chamber is preferably stationarily mounted within the housing although it is possible to have the chamber rotatably mounted within the housing.

As shown in the drawing the housing, itself, has a first end or end wall 21 and an opposed second end or end wall 22. The first end has an endcap 24 associated therewith for sealing off the housing at the first end. An entryway 28 defines the first end of the housing and provides access into the chamber 14. Both the access and the first end can be sealed when the induction coil is operating.

The induction coil 16 extends from proximate the first end wall to proximate the second end wall. The coil 16 is not limited to a helical coil such as that shown at 32. Rather, the induction coil may be a single low resistance winding, limited numbers of windings or plural windings, such as that shown.

The coil can comprise any suitable low resistance material which can be coiled or wrapped around the chamber such as, for example, copper wire, copper tubing, aluminum, aluminum windings, zinc, nickel and their alloys, and the like. Preferably, the coil is formed from copper and may be used in a dry state, cooled with a circulating fluid such as water or a gas such as air, nitrogen, argon and the like, such as shown at 30 (FIG. 2).

An exhaust port or discharge opening 26 is formed in the chamber 14 through which is exhausted any post-treatment residue via the means 18.

The means for exhausting 18, generally, comprises an exhaust tube 38 connected to an exhaust port or opening 32 formed in the chamber and extends outwardly therefrom.

Where further burning of the residue is desired, the apparatus hereof may include a blower 40 in communication with the exhaust tube 38.

The blower 40 may comprise a powered fan 42 positioned at a point displaced upstream from the chamber 14, via a conduit 41, such that upon operation, a negative pressure is created within the chamber and draws the residue upwardly and through the tube.

Where post-treatment combustion is desired, an igniter 44 placed in the tube 38 is used to ignite and then combust vapors as they travel upwardly from the chamber.

Optionally, a re-burner box or afterburner 46 equipped with a cap is disposed upstream from the igniter 44 and further incinerates any remaining residue.

Because of the force generated by the blower, any yet remaining residue from the re-burner box is then exhausted to the atmosphere through a secondary exhaust or discharge tube 50, which is in fluid communication with the re-burner box 46, as shown.

A lid 52 closes off the second exhaust tube 50 when not in use. The lid is hingedly mounted as at 54 to the terminus of the second exhaust tube 50 and opens only in response to air pressure being applied thereagainst.

A loading door 56 located at the chamber entry or second end and which is hingedly connected to the chamber is used for loading the material to be treated.

Referring now to FIG. 3, there is depicted therein a second embodiment hereof, generally, indicated at 110. This embodiment is substantially identical to that of FIGS. 1 and 2 except that according to this embodiment, a second induction coil 112 is disposed between the housing 114 and the blower-exhaust conduit 141, as shown.

The second induction coil 112 surrounds the exhaust tube 138 to further heat the exhaust ash and residue and which, in combination with the air provided by the blower, defines a “thermal oxidizer” which further reduces the waste material.

The induction coils generate sufficient heat in the chamber to pyrolyze, incinerate or otherwise reduce to ash and/or vapor the content therewithin, such as those noted hereinabove.

Referring now to FIGS. 4 and 5, there is provided a third embodiment of the present material conversion apparatus, generally, denoted at 210. According to this embodiment, the housing is arranged to extend vertically rather than horizontally.

The apparatus includes: (a) a housing 212, (b) a chamber 214 for treatment of the material to be converted, (c) an induction coil 26 which surrounds the chamber and (d) means 218 for exhausting or evacuating the content of the chamber.

With more particularity and as with the prior embodiments, the housing 212 comprises a barrel or drum 220 which is formed from any suitable insulating-type material. It is to be understood that the geometry of the barrel is not critical hereto. Thus, it may be cylindrical, rectangular or any other geometric configuration that is suitable for the materials to be treated. Preferably, the housing is formed from a refractory material or ceramic material which can easily withstand the temperatures which are generated herein within the chamber 214.

As shown in the drawing, the waste material treatment chamber 214 is disposed within the housing, substantially centrally thereof.

Although not shown in the drawing the chamber is supported within the housing by any suitable means such as bracketry, posts, stanchions or the like which are formed from materials suitable for withstanding the temperatures generated within the interior of the housing. The chamber is preferably stationarily disposed within the housing although it is possible to have the chamber rotatably mounted within the housing.

The housing has a first end or end wall 221 and an opposed second end or end wall 222. The first end has an endcap 224 associated therewith for sealing off the housing at the first end. An entryway 228 defines the first end of the housing and provides access into the chamber 214. Both the access and the first end can be sealed when the induction coil is operating.

The induction coil 216 extends from proximate the first end wall to proximate the second end wall. The coil 216 is not limited to a helical coil such as that shown at 232. Rather, the induction coil may be a single low resistance material or limited numbers of individual windings or plural segments of windings such as that shown.

The coil can comprise any suitable low resistance material which can be coiled or wrapped around the chamber such as, for example, copper wire, copper tubing, aluminum, aluminum windings, zinc, nickel and their alloys, and the like. Preferably, the coil is formed from copper and may be used in a dry state, cooled with a circulating fluid such as water or a gas such as air, nitrogen, argon and the like, such as shown at 230 (FIG. 2).

An exhaust port or discharge opening 226 is formed in the chamber 214 through which is exhausted any feed stock residue via the means 218.

The means for exhausting 218, generally, comprises an exhaust tube 238 connected to the exhaust port or opening 226 and extends outwardly therefrom.

Where further burning of the residue is desired, the apparatus hereof may include a blower 240 in communication with the exhaust tube 238.

The blower 240 may comprise a powered fan 242 positioned at a point displaced upstream or downstream (her shown as downstream) from the chamber 214, via a conduit or tube 241 in communication with conduit 238, such that upon operation, a negative pressure is created within the chamber which draws the residue outwardly and through the tube.

Although, where combustion is desired, an igniter 244 disposed in the tube 241 is used to ignite and, then, combust vapors as they travel upwardly from the chamber.

A re-burner box or afterburner 246 equipped with a cap 247 is disposed upstream from the igniter 244 and further incinerates any remaining residue.

Because of the force generated by the blower, any yet remaining residue from the re-burner box is then exhausted to the atmosphere through a secondary exhaust or discharge tube 250, which is in fluid communication with the re-burner box 246, as shown.

A lid 252 closes off the second exhaust tube 250 when not in use. The lid is hingedly mounted as at 254 to the terminus of the second exhaust tube 250 and opens only in response to air pressure being applied thereagainst.

A loading door 256 located at the chamber entry or second end and which is hingedly connected to the chamber is used for loading the material or feed stock to be treated.

Referring now to FIG. 6, there is depicted therein a further embodiment of the vertically oriented apparatus, generally, indicated at 310. This embodiment is substantially identical to that of FIGS. 4 and 5 except that according to this embodiment, and as with the second embodiment, a second induction coil 312 is disposed between the housing 314 and the blower-exhaust conduit 341, as shown.

The second induction coil 312 surrounds an exhaust tube 338 to further heat the exhaust ash and residue and which, in combination with the air provided by the blower, defines a “thermal oxidizer” which further reduces the waste material.

The induction coils generate sufficient heat in the chamber to pyrolyze, incinerate or otherwise reduce to ash and/or vapor the content therewithin, such as those noted hereinbelow.

In practicing the present invention, it is to be understood that certain elements have been eliminated for purposes of clarity, including insulation, means for powering the induction coils including an external power supply which is in electrical communication with a heat station. The heat station converts the alternating electrical current from a power supply into direct current. The station is in electrical communication with the induction coil at a first end thereof.

Also, and as noted above it is contemplated that means for rotating the housing or chamber can be deployed. This is advantageous when incinerating plastics which are usually reduced to a liquid mass. By rotating the chamber, better conversion is achieved, as well as bringing the liquid in closer proximity to the thermal oxidizer when used.

The raw material to be treated, itself, may consist of plastic, rubber, organic, as well as inorganic materials that are able to be converted to vapor and/or reduced to ash.

Although not shown in the drawing it is to be understood that a preheater may be in communication with the apparatus which preheats the material to be heated prior to it being loaded through the loading door into the chamber.

In practicing the present invention, it is, also, to be understood that certain elements have been eliminated for purposes of clarity, including insulation, means for powering the induction coils including an external power supply which is in electrical communication with a heat station. The heat station converts the alternating electrical current from a power supply into direct current. The station is in electrical communication with the induction coil at a first end thereof. 

Having thus described the invention, what is claimed is:
 1. A material conversion apparatus comprising: (a) a housing; (b) a chamber for treating the material disposed within the housing; (c) an induction coil surrounding the chamber; and (d) means for exhausting or evacuating the treated content of the chamber.
 2. The apparatus of claim 1 wherein the housing comprises an insulating element formed from refractory materials and ceramic fibers, the housing surrounding the chamber.
 3. The apparatus of claim 1 wherein the induction coil surrounds and envelopes the chamber, the induction coil generating sufficient heat to vaporize or melt waste material disposed within the chamber.
 4. The apparatus of claim 1 wherein the means for exhausting comprises: an exhaust tube in communication with the chamber, a blower in communication with the exhaust tube including a power fan for creating a negative pressure within the chamber to draw residue through the exhaust tube.
 5. The apparatus of claim 4 which further comprises an igniter disposed within the exhaust tube for combusting vapors.
 6. The apparatus of claim 4 further includes re-burner box disposed upstream from the igniter; and a secondary exhaust tube in fluid communication with the re-burner box.
 7. The apparatus of claim 4 which further comprises a lid which opens and closes the exhaust tube.
 8. The apparatus of claim 4 which further includes a second induction coil surrounding the exhaust tube, the second induction coil and the blower cooperating to define a thermal oxidizer.
 9. The apparatus of claim 1 wherein the housing is disposed along a horizontal plane.
 10. The apparatus of claim 1 wherein the housing is disposed and extends vertically. 